SHIPO Rope pump Model 1 - Bombas de Mecate...SHIPO Rope pump Model 1 Background The Rope pump is an...

SHIPO Rope pump Model 1

Background

The Rope pump is an ancient technology that, with new materials and designs, now is a very effective and low cost pump option for water supply and irrigation that is used by families and small communities. It can be produced with locally available materials in local metal workshops. Compared to other low cost hand pumps, the Rope pump has a high pump capacity and can pump from wells of 1 to 35 meters deep. It can be produced in any country and is very simple to install (no black box). If properly produced, installed and maintained, over 90% of the pumps remain functional, even many years after installation. Because of these features, the Rope pump has a high potential for Self-supply. An example is Nicaragua, where over 70,000 Rope pumps were installed. Two reasons for its success in this country were (a) technical improvements that made the pump more effective and attractive and (b) the private sector that took interest in production and sales. The pump became a commercial product so there was a “profit based sustainability”. In Nicaragua the shift from imported piston pumps to locally produced Rope pumps decreased the cost for rural water points by 60%. Close to 20% of the pumps are used for communal wells and 80% for Self-supply (domestic use, cattle watering, small scale irrigation). Due to these pumps, the total accumulated income at family level in the last twelve years was 100 Million US$. This is explained by the fact that families with a Rope pump earn an average 220 US$ more per year than families using a rope and a bucket. Using a Rope pump saves time, results in less health related cost (water is cleaner since it is not re-contaminated by the bucket) and can provide water for income generating activities such as livestock or garden irrigation.The Rope pump was introduced in 2004 in Africa based on the models from Nicaragua. Currently, there are an estimated 40.000 Rope pumps in Africa of which 10,000 in Ethiopia and 4000 in Tanzania. Pump introduction in several countries were not successful due to both technical and introduction errors. Improvements on both pump and well covers have been developed in Ethiopia and the SMART centres in Tanzania and Malawi. The drawings in this document are based on experiences in the several countries. 10-7-2014 H. Holtslag. J. Mc Gill

Parts: Part number: Sheet size:

Roughness: Dimensional tolerance: Title/Name:

Drawing AvdHeuvelSRApproved H. Holtslag

Creation 21-6-2014Approved 26-6-2014Unit : mm

Projection: Scale: 1 : 20

ROPE PUMP Model 1

Installed on a Borehole A4

by:by:

Date:Date:

© All rights reserved. No parts of this drawing and/or sketch may be reproduced, stored in a database and/or published in any form or by any means, electronic, mechanical,photocopying, recording or otherwise, without the prior written consent of the author.

10

30

20

40

50

70

90

Aquifer

Hygiënic seal

Gravel pack

10 = Handle20 = Wheel30 = Cover40 = Structure50 = Tubing70 = Slab80 = Rope / Piston90 = Guidebox

80

Casing PVC 2" to 4"






ROPE PUMP Model 1

Installed on a Dug Well A4

by:by:

Date:Date:


Aquifer

10 = Handle20 = Wheel30 = Cover40 = Structure50 = Tubing70 = Slab wellcover80 = Rope/Piston90 = Guidebox100= Well Reducer Ring

10

20

30

50

70

80

90

100

40

DETAIL A ( 1 : 2 )

Part 3 and 5

DETAIL B ( 1 : 2 )

Part 3 and 5

DETAIL C ( 1 : 2 )

DETAIL D ( 1 : 2 )

A B

C D





Projection: Scale: 1:2 1:5

ROPE PUMP Model 1

Handle - Assembly 10 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


3D VIEW

Weld20

4

230

PVC pipe as long as possible( without friction )

Cut and bend

WeldSpotwelded

Spacer ringpart 4

Spacer ring part 4 spotweldedat 2 sides ( not at top )

VIEW C ( 1 : 2 )

SECTION B-B ( 1 : 2 )

DETAIL A ( 1 : 2 )

C

B

B

1,398 kgPart 10-1S 235 JRHPipe 27 x 2,6 mm Length 770 mm11

PARTS LISTMASSPART NUMBERMATERIALDESCRIPTIONQTYITEM

A

D

E






ROPE PUMP Model 1

Handle - Galvanized 10-1 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


270 230 270

770

110°

110°

204

15

1

7

32

60°

Cutting

3D VIEW DE

SECTION A-A ( 1 : 1 )

A

A

Part 4S 235 JRHPipe 33,7 x 2,6 mm Length 7 mm 440,061 kgPart 2PVCPipe 32 x 2 mm Length 230 mm12







ROPE PUMP Model 1

Handle, PVC pipe and Spacer ring 10-2 10-4 A4

by:by:

Date:Date:


7

2,6

2

32 230

PVC - pipe 1"

3D VIEW

33,7

Spacer ringpipe 1"Galvanized

4Part

2Part


0,136 kgPart 3S 235 JRH Galv.Pipe 1" x 2,6 mm Length 60 mm230,054 kgPart 5S 235 JRFlat bar 25 x 3 mm Length 100

mm25


A A






ROPE PUMP Model 1

Bushing - Assembly 10-3 10-5 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


10 80100

3

11 (2X)

50

6030

25

6 (1X)

3

3 Weld(2x)

3D VIEW

5

3

Pipe 1" xGalvanized

Part

Part

27,7*

* Inside diametre 0,5-0,8 mm more than outside diametre of handle.


DETAIL B ( 1 : 2 )

DETAIL C ( 1 : 2 )

A

A

BC

0,024 kgPart 5Steel 8.8 GalvanizedBolt M10 x 20 mm251,320 kgPart 6Car tire 14"Wheel rim 14"160,035 kgPart 3S 235 JRFlat bar 25x3mm Length 55/64mm630,096 kgPart 2S 235 JRRound 10 mm Length 156 mm620,012 kgPart 4Steel 8.8 GalvanizedNut M10240,195 kgPart 1S 235 JRH Galv.Pipe 1" x 2,6 mm Length 100 mm11







ROPE PUMP Model 1

Wheel - Assembly 20-1 to 20-6 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


26 - 3425

11,6

10

-156

356

(14")

440

100

2,6

* 1"

1570

Nut M10

M10x20

11 (2x)

Depends on tire used( should be tight fit )

6

3

2

1 4

5

3

3

3

* Should fit over handle

DETAIL A ( 1 : 2 )

0,940 kgPart 30-1SteelGalvanized sheet 1000x200x0,6mm11


A






ROPE PUMP Model 1

Cover 30-1 A4

by:by:

Date:Date:

ISO 2768-1-f /-2-H


745 110 45

200

7

1000

325

325

350

18 18

35 (4x

)

3D VIEW

5 (8x)

5 (4x)

10

2

1815

745

5

(4x

)

0,6

111

7

38,5

Production:1) mark holes etc. using a jig2) drill holes and cut at, detail A

3) bend at (C) 180

4) bend at (D) 905) mount in pump, drill additional holes6) mounts rivets 5

7) case of bolt, use galvanized bolt M6x15mm

Bend

D 9

0°

Bend

C 180

°

0,922 kgPart 30-1SteelGalvanized sheet 1000x200x0,6mm11







ROPE PUMP Model 1

Cover 30-1 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


108°

108°

550

310

3D VIEW

Cover Part 30-1sheet folded

0,015 kgPart 30-3S 235 JRFlat bar 25 x 3 mm length 30 mm

43

0,579 kgPart 30-2S 235 JRG 2Angle profile 25 x 25 x 3 Length 520 mm

22







ROPE PUMP Model 1

Cover support - Assembly 30-2 30-3 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


520

52025

220 80

12,5

12

30

25

3

11

3D VIEW

COVER Part 30-3

COVER Part 30-2

25

2535 (6x)

10

7

18

29

3 2

3






ROPE PUMP Model 1

Structure - Assembly 40 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


200400

920

250

250

Part 1 - 2x Angle iron 25x25x3-100

Part 2 - 4x Gi pipe ½"-950

Part 3 - 4x Gi pipe ½"-180

Part 4 - 1x Gi pipe 1¼"-30

Part 9 and 11 - Hook

Part 10 - 2x Spacer ring

Part 5 - 2x Gi pipe ½"-120 Flat

Part 6 - Outlet support

Part 7 and 8 - Outlet support

3D VIEW

35

15

30

11* Steps production:

1) - Make pipe end flat2) - Drill hole 113) - Bend pipe

*






ROPE PUMP M0del 1

Structure - Parts 40 -1-6-7-8 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


10 80

100

15 25

25

311 (2x)

Part 1

70

20

80

30

Bolt M10x25GalvanizedNut M10

3 Weld

Gi pipe ¾"

Nut M10

Bolt M10x25Galvanized 3 Weld

3 Weld

Gi pipe ½"

Gi pipe 1½"

Part 7 Part 8

Part 6

0,011 kgPart 40-10S 235 JRH Galv.Pipe 26,9x2,6mm Length 7mm2100,206 kgPart 40-9S 235 JRH Galv.Pipe 21,3x2,6mm Length 170mm190,062 kgPart 40-11S 235 JRH Galv.Pipe 26,9x2,6mm Length 40mm111







ROPE PUMP Model 1

Structure - Blocking system 40 -9-10-11 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


40

120

40

47

Gi pipe ½" x 170

40Gi pipe ¾" - 40

70°

81°

Flat

3D VIEW

Spacer ring spotwelded

7

Gi pipe ¾"

Part 11

Part 9

Part 10






ROPE PUMP Model 1

Tubing - Assembly 50 A4

by:by:

Date:Date:


200

PVC pipe 1¼" 4

PVC pipe 1¼" 1PVC pipe 1¼" 2

Tee 1¼" 3

Elbow 1¼" 5

PVC pipe 1¼" 6

Diametre pump pipe depends on depth 1¼" 0-5m >4" casing

1" 5-10m >3" casing

¾" 10-20m >3" casing

½" 20-35m >2" casing

100

PVC pipe ½" - 1" 10

Guidebox 11

1000Piston distance

Reducer 1¼" 7Cap 4" 8

PVC pipe 4" 9


VIEW B ( 1 : 10 )

A A

B






ROPE PUMP Model 1+2

Slab / Wellcover - Assembly 70-1 to 8 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


3D VIEW

900

200

70

50

400

200

PVC pipe 4"

4560

Part 2 - Rebar 6 - 800

Part 1 - Cement slab-600 to 800

Part 3 - PVC cap 4"

Part 4 - PVC pipe 4"x 3

Part 5 - 4x Bolt M10x25 Galvanized

Part 6 - 2x Round bar 8mm-240



10

Part 3 - PVC cap 4"

Hole 1¼"

Hole ½"

or - ¾"or - 1"


A A






ROPE PUMP

Piston 80 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


6

B *

A *

5

C *

D

* Size depends on pump pipe diametre inside. Pipe A * B ** C ** D½" 15,3 11 13 11¾" 20,3 13 15 121" 27,3 20 20 13 * Tolerance 0,2 ** Tolerance 0,5 Based on pipes ½" OD = 20 ID = 16 ¾" OD = 25 ID = 21 1" OD = 32 ID = 28 OD Outside diametreID Inside diametre

3D VIEW


A A






ROPE PUMP

Guidebox Cement ¾" 90 A4

by:by:

Date:Date:


55

50100

100

100

40

25

-30

100PVC pipe ¾" - 215 *

PVC pipe 1" - 165 *

* This guidebox is for ¾" For pump pipes of 1"and ½" pump pipe + return pipe are different ½" - ¾" 1" - 1¼" ** Use small glass bottle or Galv. pipe ¾"

**

3D VIEW

made off PVC pipe 3"

300


SECTION B-B ( 1 : 2 )

A

A

B B






ROPE PUMP Model 1

Guidebox - Assembly 90-1 to 9 A4

by:by:

Date:Date:

ISO 2768-1-f / -2-H


1

3

2

7

8

9

PVC pipe ¾"

PVC pipe 1"

Gi pipe 1"

Gi pipe ¾"Steel

Steel

Gi pipe ½"Steel

Gi pipe ½"Steel25

12

25

40

PVC pipe ¾" Lock

6

5

4

Gi pipe ½"-70Steel

Gi pipe ¾"Steel

31

150 In case the pump pipe is

-½" return pipe = ¾"-1" return pipe = 1¼"

3D VIEW

Guidebox has to fitin casing.min.tolerance 5 mm

4070

30°

2.5

2.5

2.5

2 Weld






ROPE PUMP Model 1

Well Reducer Ring 100 A4

by:by:

Date:Date:


195

20038

0

50

397

402

87° 87°

402

397

AA

Cement blockmade in moulds

Position pump

12 x cement block ( for wells rings of 80 to 110 cm- wells diametre 110 to 140 cm two rings, needed )

Close with cement 1 : 4

Rim ( Angle to slab of two degrees, to soak pit )

Filled with cement

3D VIEW

To soak pit

Model 3 ( Pole model)Model 2 ( economy model)Wheel cover Optional

Model 1 Ball bearings optional

Suggestions for minimum quality for Rope pumps All models fit on both hand dug wells and boreholes. The pump model no. 1 is fit for small communities and all 3 models are fit for Self-supply in households. The recommendation on the minimum quality are summarized below.

Parts Suggestions Model 1 (improved model) Suggestions model 2 & 3 (economy & pole model)

Wheel cover

-sheet cover 0,5 mm Galvanized sheet Preferred 0.6 mm Wheel cover is optional

-Sides Bent rim if less than 1 mm

-Mounting Bolts M6 or pop rivets 5mm, 2 at each connection

- Bolts cover to M6 x 15 galvanized or M10

-Cover Support 12mm rebar or 20x20x2 mm Angle iron or Gi pipe ½”

Wheel

- Diameter 14” 14”

-Number of spokes 6 4, with clamps in between

- Material of spokes Rebar 10 mm or galv. Pipes Rebar 10 mm or galv. Pipes

-Tire quality Good quality, straight, soft rubber Good quality, straight, soft rubber

- Bolts /Nuts M10x25 Galvanized Optional if uses bolts than M10x25 Galvanized

Handle

Pipe ¾” Galvanized steel pipe.Wall thickness min. 2,2 mm

½” Galvanized steel pipe.Wall thickness min. 2 mm

Handle grip 1” PVC pipe, Wall thickness 2 mm ¾” PVC pipe, wall thickness 1.5 mm

Bushing 1”, wall thickness 2,5-3mm Galvanized steel pipe ¾”, wall thickness 2,2 – 2,5mm Galvanized steel pipe

Clearance 0,5- 0.8 mm 0,5-0,8 mm

Length bushing 60 mm 60 mm

Bushing strip Strip 25x3 mm NA

Diameter of the oil hole 6 6

Welding / Painting

All welded parts Clean weld slack, Paint with anti oxide +gloss paint Clean weld slack, Paint with anti oxide +gloss paint

Pump structure

-Pipes ½” Galvanized steel pipe Wall thickness 2 mm ½” Galvanized steel pipe. Wall thickness 1.6 mm

Bushing support Angle iron 25x25x2 Angle iron NA

Recommendations on technical aspects The recommendations are with objectives (a) to improve quality and durability of the Rope pumps and (b) reduce the cost of the Rope pumps to increase the potential uptake in the Self-supply market. Use one size prefabricated slab of 90cm and well reducer rings eventually with prefabricated tapered blocks. This will drastically improve quality of the well head, increase hygiene and combined with standardised slabs can reduce cost of installation.

No 10 Handle/ bushings• Clearance between bushing and pipe of handle 0.5 to 0.8 mm. So difference between outside diameter

of handle and inside diameter bushing maximum 0.8 mm. This is important for alignment and good lubrication. If the bushing has more clearance, the diameter should be reduced by cutting out a slot.

• Make the diameter of the oil hole 6 mm and put the oil hole on top. This makes oiling of bushings much easier for users. Eventual rain that enters in the oil hole is not a problem and even an advantage since rain will clean the bushings.

• Length grip 270 mm. This will reduce cost of material, reduce danger of bending of the handle and is long enough as experienced in the pumps installed.

No 20 Wheel• Make clamps long enough to be able to close them when rope starts slipping.• Use only galvanized bolts. Also spokes can be made of ½”Galvanized pipe and the clamps of

¾”galvanized pipe, wall thickness 2.5 mm.

Block system Hook of Rebar or Gi pipe NA or Gi Pipe

Outlet pipe and return pipe support Make of ring of Gi pipe NA or ring of Gi pipe

Name plate Aluminium . Data incl. Producer, Tel No, Ser. No

Aluminium . Data incl. Producer, Tel No, Ser. No

Rope/ pistons 1m distance, 0,5-0.8 mm clearance

1m distance, 0,5-0.8 mm clearance

Pump PVC parts

Pump Pipe diam [well depth] Outside diam. - Inside diam. Outside diam - Inside diam

1” [1 – 10m]¾” [10- 20m]½” [20- 35m]

32mm- 28 mm25mm- 21 mm20mm- 16 mm

32mm- 28 mm25mm- 21 mm 20mm- 16 mm

Outlet pipe

-Outlet pipe 1 1/4” Outside diam - Inside diam Outside diam - Inside diam

40mm- 36 mm 40mm- 36 mm

-Tee 1 1/4” Good quality, tight fit with reducer Good quality, tight fit with reducer

-Reducer 1 1/4” - 1”

-Reducer 1 1/4” - ¾”

-Reducer 1” - ½”

- Elbow 1 1/4”

- Return pipe Poly Pipe or PVC pipe. 1 size bigger than pump pipe Poly Pipe, PVC pipe. 1 size bigger than pump pipe

Well head. Cover, Apron, Soak pit

Well cover Diameter 90 cm Diameter 90 cm

Reinforced with rebar min dia 8mm distance 15 cm Reinforced with rebar dia 6 mm distance 15 cm

PVC pipe 4 Inch length 15 -20cm PVC pipe 4 Inch length 15 -20cm

PVC Cap, cover Round or Flat top Cap Round top Cap

Top of casing above Ground level 20 cm NA

Top of Casing to Apron 10 cm NA or 10 cm

Diameter apron 1 – 1.8m 1 - 1,8 m

Dist. apron to soak pit 3 -5m 3 -5m

Outlet Pump Opposite soak pit Opposite soak pit

Apron slope to soak pit 0-5cm 5 cm

Apron height 5-10 cm 5

No 30 Wheel cover• Use galvanized sheet, thickness of minimum 0.5 mm• In case of 0.5 or 0.6 mm thickness, bend the rims to make the cover stronger. If sheet of 1 mm is used

bending is not needed.• Drill holes in part where the sheet is bend to avoid cracking of the sheet.• The wheel cover supports can be made of Angle iron 25x25x3mm or Gi Pipes of ½”. • For mounting the cover support use 3 pop rivets of round 5 mm.

No 40 Pump structure• Make a narrow structure, dimensions of base 200 x 400 mm. This will reduce the cost of material and is

less work since bending of the wheel cover support is not needed • Use the system of bended legs; advantage more flexibility in the mounting of the pump in case the

distance between the bolts in the well slab (well cover) are not 100% exact. • Have the handle at the height of the belly button of the person pumping, so the height of the handle

should be 80 to 90 cm. Make the legs of the new models 95 cm, so the height of the handle will be around 90 cm, (the leg at the low end is bent).

No 50 Tubing / PVC pipes and parts• Pump pipes with the same in and outside diameter. Work on a supply chain of standardized PVC pump

pipes.• Proposed dimensions are mentioned in the table below (see also Annex 1). In general wall thickness of

all pipes should be 2 mm. • Pump outlet pipes of 1 ¼” so they fit in jerry cans. • Make a smooth entrance on PVC pipes. Make so called trumpets on pipes in guide boxes and return

pipe. To make this, a jig (Trumpet tool).

No 60 Cap / casing• Make the caps and the 4 inch pipes in such a way that water cannot flow back into the wells.• The holes in the cap for the pump pipe and return pipe should have a tight fit with the pipes.

No 70 Slab/ well cover • In field surveys it appeared that a major problem with the Rope pumps is low quality of well covers,

pump installation so water leaking back in the wells. To improve this always make a well ring on which a slab can be mounted. It is suggested to use slabs with a diameter of 90 cm. to reduce risk of breakage, transport ease of removal by users. The logic of using a small, 90 cm slab is that it can be thin like 5 cm and still has the same strength than a slab of 120 cm which has to be 6 to 7 cm to make it strong enough. The small slab is much easier to transport les risk to break and it is also easier for families to remove in case of well cleaning.

• Test the cement well reducer ring. This reduces the diameter of the top of the well (well ring) to 80 cm so with a slab of 90cm the well can be covered.

• The use of manholes is strongly discouraged because of water leaking back in the well. This is due to the design and often poor construction of the well cover as was observed in the field visit. In general experiences is that when there is a problem with the pump, people tend to go back to the rope and bucket and remain using the bucket which is “back to zero”.

• In case the widely available cheap 4 inch pipe is used, make the part used in the slab stronger by using a double piece of pipe. This will make the 4 inch pipe more resistant to damage.

• Bolts used to mount the pumps should be welded well to the reinforcement bar structure. Use galvanized bolts M10x 25 mm.

• Place the pump a bit aside on the slab. The person who is pumping can stand on the slab. See drawings.

No 80 Rope /Pistons• Pistons can be Rubber or HD PE injected • Make the diameter of the pistons 0.5 - 0.8 mm smaller than the inside diameter of the pump pipe. With

a greater diameter, the pump efficiency goes down. When it is smaller friction will occur especially in the smaller pumps pipes of ¾” and ½” since PVC pipes are not always exactly round and the same diameter.

• It is strongly suggested to use standardized PVC pipes and standardized pistons.

No 90 Guide box• Use guide boxes made completely of galvanized tube. See also drawings.• Or use cement guide boxes. The cost will be the same or lower than metal guide boxes, but will avoid corrosion in water with low PH. For deeper hand dug wells, the weight of the cement guide box will help to keep the pump pipe straight.• The metal and cement guide boxes should be 5 mm smaller than the inside diameter of the 4 inch pipe in the slab.

Well head / ApronBased on the field surveys a major problem in Rope pumps is the low quality of the well heads. Pumps are to low or too high, well covers are not straight or broken. There is often no hygienic seal so with rains well rims are collapsing and water can flow into the well. So a general suggestion is to improve quality of well heads. Suggestions are;• Install a well ring on top of which the slab is mounted, this to avoid water leaking back in the wells. If

this ring is at the same time a reducer ring, the diameter of the slab can reduce.• Test the system of the tapered prefabricated blocks for the well reducer ring. This can become the

activity of well diggers and/or local masons. Make the inside diameter of the well ring 80 cm plus / minus 5 cm which allows the diameter of the slab to be 90 cm, which is still small and easy to transport.

• For wells of 90 - 110 cm use one well ring and reduce hole to 80 cm. • For wells of 110 to 130 cm diameter use 2 rings of blocks.• Install the well reducer rings a bit conical and put a few wires around the ring. The conical shape will

avoid water leaking back in the well and is stronger, more resistant against breaking than a flat rings.• Put some basic reinforcement in the well blocks like 5 pieces of 40 cm black wire which will hardly

increase the cost but will avoid braking of the blocks.• Make an apron around the slab to seal the well and avoid leaking and a soak away to avoid at all times

water pools near the well.• At some pumps the soak away is used as a drinking place for cattle. It is strongly suggested to avoid

this since the leak water from slab and apron is contaminating the well. In case of cattle water it is much better to make a separate pit of bucket for drinking.

• Promote / train well diggers to make wells with maximum diameter of 90 cm. Calculations indicate that, compared to wells of 120 cm , a 90cm well reduces 80% in volume of material to take out so reduction of labour. Also with the small diameter only one well ring is needed.

Pump models Based on the survey and tests, 3 pump models are recommended in order to give potential a range of options:

Model 1 (improved Rope pump model)• The Model 1 is standard with bushings• As an option it can be made with ball bearings. If ball bearings are used good quality and sealed

bearings are needed. Also a grease pump should be included in the pump. Selling a pump without a grease pump will cause problems.

• An Allan key should also be provided as a requirement with the pump with ball bearing.• In case of ball bearings, use 2 bolts to fix the handle to avoid it will get loose.• The total additional costs for a model with ball bearings is estimated at 600 Birr.

Model 2 (economy model)• This model is very basic without any bolts in the pump structure, no cover, a handle of ½” no return

PVC pipe. It si completely made of Galvanzed pipes so no or little corrosion• As an additional parts a well cover and a return pipe can be sold. • The total cost (material and labour) of Model 2 is much lower than Model.

Model 3 (pole model)• This Model is the most basic low cost Rope pump model mounted on poles and 2 pumps like this were

installed in the test field.• It consist of a handle with bushings and a wheel which is mounted with bolts on the handle. By placing

the poles in an angle, the length of the handle is reduced.• After some initial problems the users of the Model 3 were very satisfied;

This model again can be some 30% cheaper than Model 2 with the advantage that it can be installed without a well cover. So if families do not have much money or do not want to take a loan , this can be a real first step model. Lateron when they have more money, a well cover can be installed or they can opt for a Model 2 pump.

Lower cost models, Model 2 ( economy model with options for a wheel cover , and Model 3 (pole model) see pictures under Use for Households (Self-supply). With new low cost pump models and improved quality of pumps and well head, Rope pumps have a large potential to scale up Self-supply.

Model 1 Ball bearings optional Model 2 ( economy model)Wheel cover Optional Model 3 ( Pole model)

Suggestions for minimum quality for Rope pumps

All models fit on both hand dug wells and boreholes. The pump model no. 1 is fit for small communities and all 3 models are fit for Self-supply in households. The recommendation on the minimum quality are summarized below.

Recommendations on non technical aspects Besides technical aspects, there are also a number of non technical aspect which are essential for a successful dissemination of Rope pumps like. 1. Poor daily maintenance. Many users do not adjust the rope or oil the bushings in time resulting in poor

pump functioning and worn out bushings. (In Nicaragua Rope pumps of 20 years old still have the original bushings because they are oiled every week);

2. Make several models and prices so customers can choose3. Rope pumps are simple but “Simple is not easy”. For any producer it is essential to realise, bad

pumps = bad image = less sales;4. The dissemination of free pumps via NGOs and is distorting the development of a sustainable supply

chain;Some suggestions for improvement are:• To improve the quality, it is a suggestion to make example (gold) models for each pump producer

including production jigs. A number of jigs were made in the 1st and 3rd mission.• Examples and production jigs of the new models are needed which could be copied and send out to all

Rope pump producing companies.

Certification• Improve the quality by certifying or approving the producers of these technologies; • This is in the interest of the government and should be effected by a governmental body. Until there is

such a body the partners should support. • Operation/ Maintenance / repairs• Improve maintenance by more and better training of users in daily maintenance;• Most important maintenance is the adjustment of rope, (rope should not be too tight, not be too loose)

and weekly oiling of bushings with new oil!!;• Promote the custom of maintenance by a slogan like “No oil - No pump’’ • A pump installation should include a (laminated) maintenance sheet and a 0.3 l bottle with new oil (10W

40). Do not use grease or used oil!;• General repairs like adding a piece of PVC pipe, replacing bushings etc are not done by users. In each

area there should be technicians who can do this work on a commercial base; • Technicians can be of pump producing companies, pump installers or metal workshops who can do

repairs as one of their activities.• It should not be done by NGOs or local government, since this will prevent a sustainable commercial

supply chain from building up!!• NGOs and governments should rather invest their water funds in awareness training of the local private

sector, quality control, building up supply chains, evaluation, and enabling funding options for instance micro credits, monitoring etc.

Training• In general many problems are caused by a lack of knowledge of both users and caretakers. Serious

investment in long term and follow up training of production quality, installation, maintenance and repairs, organisation of maintenance, (ej Circuit riders) are recommended .

• One option to guarantee knowledge and training in the long term, is a National WASH training centre where all knowledge is concentrated and which has the capacity for trainings. Then smaller training centres can start later on in the regions. Examples of such training centres are the so called SMART Centres in Tanzania and Malawi.

References• Alberts. H., Zee. J van der. 2004. A multi sectoral approach to sustainable rural water supply in

Nicaragua: The role of the Rope handpump. Presented at SIMI conference Switzerland, 2004. Online available at: http://www.bvsde.paho.org/bvsacd/cd29/sectoral.pdf [May 2014]

• Gorter. A. (1998). Childhood diarrhoea and its prevention in Nicaragua. PhD Un. Maastricht• IRC 1995 Nicaraguan experiences with the Rope pump. Online available at: http://www.washdoc.info/

docsearch/title/113703 [Accessed on 30th of May 2014]• Japan International Cooperation Agency (2013). Report Rope pump users: Survey in three regions.

Powerpoint presentation. • MetaMeta , Holtslag H. & Tefera T (2013).Report Programme Rope pump improvement Hailu Debela.

T. (2013) Monitoring water supplies and sanitation in Ethiopia. National WASH Inventory Office. Minstry of Water, Irrigation and Energy.

• PH hydro engineering consulting (2014). Baseline survey on project implementation woredas. Japan International Cooperation Agency.

• Sutton, S., Butterworth, J., & Mekonta, L. (2012). A hidden resource: household-led rural water supply in Ethiopia. IRC International Water and Sanitation Centre, the Netherlands. ISNB 978-90-6687-080-2

• Sutton.S & Hailu.T (2011). Introduction of the Rope pump in SSNPR, and its wider applications.Ripple working paper 22. Online available at: http://r4d.dfid.gov.uk/PDF/Outputs/RIPPLE/working-paper-22.pdf [March 2014]

• Sutton.S, Mammo.A. , Butterworth. J. & Dimtse.E. (2011).Towards the Ethiopian Goal of universal access to rural water. Ripple Working paper 23 online available at: http://r4d.dfid.gov.uk/pdf/outputs/ripple/working-paper-23.pdf [March 2014]

Information on scaling up safe water: www.300in6.org Information on Rope pumps www.ropepumps.org

Different pumps

Model 3 Mounted on polesModel 2 Economy model, bent legs

Model 2 Economy model, Bottom structure Model 1 Bushings, Bend legs. Pump pipe and return pipe via the 4 inch pipe. Improved model

Model 1 Wide structure, Ball bearings, bottom reinforcement. JICA model

Model 1 Narrow structure, Ball bearings, and Bent legs. Improved model

Corrosion of bolts, trumpet on return pipe poor qualityProblems with cover of sealed model

Heavy Guide box. New models use 60% less metal and are galvanised materials

Lack of oiling resulting in broken handles

To much clearance in bushing resulting in extra wear Use of ball bearing but low quality. If ball bearing are used than sealed models with grease nipple

Pump high since it is mounted on a parapet. In this case short base model should have been used or a platform should be installed.

Large diameter outlet pipe so pipe does not fit into the jerrycans. Suggestion to reduce diameter outlet pipe to 1 ¼”

Lack of soak pit so water around the well Lack of apron so water leaking back in well

Return pipe not sealed, PVC parts broken, Pipe end cap is cut and has large holes so water leaks back in well.

Problems in Pump installation

Jigs and tools Incl. socket and trumpet tools, end caps, cement guide block.

Mounting of Rope pump Model 2.A frame, economy model. Instead of welding angle iron and rebar, legs are bend and have a hole so less material and less welding

Producing well cover with M10 Galvanized boltsAligning the outlet support

Finished well slab Preparing well slab

Inside diameter is 80CmMaking well ring reducer with bricks

Installing pole model pumpMaking demonstration

Making cement guideblock

The manhole makes the well cover weak. Like in this case there is a crack cracked in the corner so another source for leaking water in the well.

Well cover with Manhole. Water can leak back in well since there is no rim around the hole.

Well reducer ring made of tapered blocksFamilies/masons in Butajera trained in making blocs with moulds

Special tapered blocks to make a well ringMonitoring pumps in the field

Here water is pumped for cattle. The cattle drink from a separate drinking bucket away from the pump.

Here a hose is connected to the outlet to transport water to the garden on the other side of the house

Pump model 2 used for productive use. Here the pumps is used for irrigation of a garden of 300 m2

The outlet pipe of 1 ¼ “ it fits in jerry cans

Here the well slab is not sealed well on the well rim. The inlet of the return pipe is not good. It requires a nice smooth entrance, a so called trumpet which can be made with a trumpet tool.

Good example of Soakpit, all water goes to the pit The pit is filled with stones so no water is visible so not drinking of cows, no mosquitos etc.

Bad example of Soakpit, The pit with stones was blocked and a new hole for cattle was made. This results in contaminated water.

Here clamps are installed but length is not goodWheel with 4 Spokes of GI pipe. Clamps in between are missing

Lubrication of bushings. The oil hole should be on top Pump with ball bearings. In this case also supply a grease pump

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